The process started with raw 3D prints done in PLA, which were welded, sanded, primed, and wetsanded to a smooth finish.
The visor for Guy/Manuel's helmet was challenging - with a $3,000 quote from Xometry motivating custom fabrication, I decided to go down the vacuum forming route. To strengthen the PLA material to resist the intense heat and pressure, I added a thick coat of photopolymer resin on the outside surface and a carbon fiber rib along the interior. With these modifications, the mold would be able to survive the vacuum forming process.
With the vacuform process complete with 1/8" PETG sheet at ~200C, a test fit was done to test for any warping and confirm visibility.
After a tint test (shown below), a spray one-way tint was applied to the gold helmet. Thomas' helmet visor was cut from a grinding face shield, then heated to form around the curvature of the piece.
With time running low until Halloween, a quick and dirty set of glove armor was made for both costumes by heating spare PETG sheet and pressing onto my hand (wearing an oven mitt). The excess material was trimmed and sanded to the accurate shape by hand, then painted using the same process as with the helmets for a consistent color.
After purchase of leather jackets and balaclavas, the costumes were finished by gluing the armor to cotton gloves using E600 (a flexible glue).
